Method and apparatus for forming final-shaped containers using liquid to be contained therein

ABSTRACT

There is provided a system, a method and preform suitable for executing liquid forming of the preform into a final-shaped container. The present technology includes various improvements to methods, apparatuses, and systems for forming final-shaped containers from preforms using a liquid destined to be contained in the final-shaped container.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/961,385 filed 10 Jul. 2020, which is a national phase entry ofPCT/CA2018/051678 filed 28 Dec. 2018; and claims priority from US PatentApplication No. 62/616,014 filed 11 Jan. 2018, the entire disclosures ofwhich are incorporated herein by reference thereto.

FIELD

This application relates to methods, apparatuses, systems and preformsfor molding containers in general and, more specifically, for moldingpreforms into final-shaped containers using a liquid, the liquid being aproduct to be contained in the final-shaped container.

BACKGROUND

In many typical molding processes, the molding process includes cyclesof bringing two or three complementary mold portions holding mold partswith features defining an article to be molded into a close proximity ordirectly into contact. Generally one of the complementary parts isstationary, and the other is moveable with respect to the stationarypart. During the molding process, a preform (as an example of the moldedarticle being produced) can be produced. The preform is a precursor to afinal-shaped container. The preform can be reheated and formed into thefinal-shaped container by a stretch blow molding process. Such a twostage process (first making the preform and then reshaping the preforminto the final-shaped container) is useful in various circumstances,most notably, where the production of the preforms and the filling ofthe final-shaped container are separated in space and/or time.

It is typical in this art for the production of preforms to be performedby a first entity (typically known as a “converter”) and the forming ofthe final-shaped container and the filling the final-shaped containerwith the content to be executed by a different entity (typically knownas a “filler”),

It is known in the art that liquid, specifically a liquid product to becontained in the final-shaped container, can be used for forming thefinal-shaped container. This process is generally referred to as “liquidforming” or “form filling” of the final-shaped container from thepreform.

One example of such a process is disclosed in U.S. Pat. No. 9,259,887(issued to Fevre et al. on Feb. 16, 2016). There is disclosed a methodof forming a container that includes: a partial expansion first step(E1) during which the container is filled with a pressurized blowing gas(G); a second step (E2) of filling the container during which thecontainer is filled with a filling liquid (L) that expels the blowinggas (G) through an outlet orifice; and a third step (E3) during whichthe contents of the container are put under a pressure (HP) so as tomake the container conform to its final state (18D), characterized inthat, during the filling second step (E2), the ratio of the flow rate ofthe incoming filling liquid (L) to the flow rate of the outgoing blowinggas (G) is controlled so as to allow the container to continue to expandduring this second step (E2).

SUMMARY

Developers of the present technology have developed various embodimentsthereof based on their appreciation of at least one technical problemassociated with the prior art approaches to forming final-shapedcontainers using liquids and, particularly, to preventing gate portionsof preforms to be stretched from cooling too quickly due to liquidexpansion.

Without wishing to be bound to any specific theory, embodiments of thepresent technology have been developed based on a premise that gateportions of the preform may cool overly rapidly when liquids are used toperform the blow-molding. The liquid, generally a liquid product to becontained in the final-shaped container (such as a beverage, as oneexample), will generally cause the stretching to initiate from the neckportion of the preform and to gradually “move” towards the bottomportion of the preform. In those cases where the gate portion of thepreform cools too rapidly due to the use of liquid stretching, thebottom portion of the final container (including the gate portion and,potentially, the lower portions of the body portion of the preform) maynot fully form to the shape required for the final-shaped container(i.e. it will not fully “fit” the cavity of the stretch cavity), or mayform with defects (for example, by overstretching some portions or withcrystallization defects).

There is therefore a need for solutions that aid in preventingmalformations of bottom portions of final-shaped containers when moldingfrom preforms using a liquid destined to be contained in thefinal-shaped container.

As such, in accordance with a first broad aspect of the presenttechnology, there is provided a method of forming and filling afinal-shaped container using a liquid, the liquid being a product to becontained in the final-shaped container. The method comprises forming apreform by injection molding in an injection molding machine; removingthe preform from the injection molding machine by an end of arm tool;forming a prepared preform by blowing a base portion of the preform to astretched size, the stretched size being less than the size of a base ofthe final-shaped container; relocating the prepared preform to a formingcavity of a forming machine for simultaneously forming and filling usingthe liquid to be contained in the final-shaped container, the formingcavity having an internal surface; sealably connecting a nozzle onto anopening of the prepared preform; and stretching the prepared preforminto conformity with the internal surface of the forming cavity byfilling an interior of the preform with the liquid through the nozzle,pressure of the liquid entering the prepared preform causing theprepared preform to expand.

In some embodiments, the end of arm tool includes a forming cavityadapted for forming the prepared preform; and the removing the preformfrom the injection molding machine by an end of arm tool comprisespositioning the preform in the forming cavity; and the forming theprepared preform comprises blowing the base portion to the stretchedsize by the end of arm tool.

In some embodiments, the removing the preform from the injection moldingmachine by an end of arm tool further comprises positioning the preformin a forming cavity of a preparation station, the preparation stationbeing separate from the forming machine and the end of arm tool; and theforming the prepared preform comprises blowing the base portion to thestretched size by the preparation station.

As such, in accordance with another broad aspect of the presenttechnology, there is provided a method of simultaneously forming andfilling a final-shaped container from a preform using a liquid, theliquid being a product to be contained in the final-shaped container.The method comprises locating the preform in a mold cavity having aninternal surface; sealably connecting a nozzle onto an opening of thepreform; inserting a stretch rod through the nozzle into the opening ofthe preform, at least a lower portion of the stretch rod sealablyconnecting with an interior surface of the preform to at least partiallyisolate a gate portion; and stretching the preform into conformity withthe internal surface of the mold cavity by: filling an interior of thepreform with the liquid through the nozzle, and extending the stretchrod farther into the gate portion.

In some embodiments, the stretch rod includes a deformable memberconfigured to at least partially isolate the gate portion of the preformfrom the liquid when extended; and when filling an interior of thepreform with the liquid through the nozzle, the liquid causes thedeformable member to extend out from the stretch rod to contact theinterior surface of the preform to form a temporary seal to at leastpartially isolate the gate portion from the liquid.

In some embodiments, the deformable member is a rubber cup disposedabout a lower portion of the stretch rod.

In some embodiments, the rubber cup radially extends from the stretchrod.

In some embodiments, the deformable member is repositionable between anengaged configuration and a disengaged configuration, in the disengagedconfiguration the deformable member being dimensioned to pass through aneck opening of the preform.

In some embodiments, the deformable member is repositioned into theengaged configuration by the pressure of the liquid filling the interiorof the preform.

In some embodiments, the deformable member is repositioned into thedisengaged configuration by a decrease of the pressure of the liquidfilling the interior of the preform.

In some embodiments, the stretch rod includes a controllably-extendiblesealing member for selectively and at least partially isolating the gateportion of the preform from the liquid; and the method further comprisesactuating the controllably-extendible sealing member to extend out fromthe stretch rod to contact the interior surface of the preform to form atemporary seal for at least partially isolating the gate portion.

In some embodiments, the controllably-extendible sealing member isactuated by a machine control unit operatively connected to the stretchrod.

In some embodiments, the stretch rod includes a selectively heatabletip; and the method further comprises activating the selectivelyheatable tip for heating at least the gate portion of the preform beforethe stretching of the preform.

In some embodiments, the method further comprises prior to thestretching the preform into conformity with the internal surface of themold cavity: performing a preliminary stretch of the preform by moldingthe preform to a partially stretched configuration.

In some embodiments, the deformable member is a rubber air bladderdisposed about a lower portion of the stretch rod.

In some embodiments, the rubber air bladder is repositionable between anengaged configuration and a disengaged configuration; in the disengagedconfiguration, the rubber air bladder is dimensioned to pass through aneck opening of the preform; and the rubber air bladder is convertedfrom the disengaged configuration to the engaged configuration byinflating the rubber air bladder.

In some embodiments, the stretch rod includes a controllably-deformablerubber air bladder for selectively and at least partially isolating thegate portion of the preform from the liquid; and wherein the methodfurther comprises inflating the controllably-deformable rubber airbladder to extend out from the stretch rod to contact the interiorsurface of the preform to form a temporary seal for at least partiallyisolating the gate portion.

As such, in accordance with yet another broad aspect of the presenttechnology, there is provided a method of simultaneously forming andfilling a final-shaped container from a preform using a liquid, theliquid being a product to be contained in the final-shaped container.The method comprises locating the preform in a mold cavity having aninternal surface; sealably connecting a nozzle onto an opening of thepreform; inserting a stretch rod through the nozzle into the opening ofthe preform, the stretch rod including a selectively heatable tip;heating the selectively heatable tip for heating at least a gate portionof the preform; and stretching the preform to conform to the internalsurface of the mold cavity by: filling an interior of the preform withthe liquid through the nozzle, and extending the stretch rod into thegate portion.

As such, in accordance with yet another broad aspect of the presenttechnology, there is provided a method of simultaneously forming andfilling a final-shaped container using a liquid, the liquid being aproduct to be contained in the final-shaped container. The methodcomprises forming a preform, by injection molding, in a mold cavitydefined at least in part between a mold core and a mold cavity portion;removing the preform from the mold cavity portion, the preform remainingon the mold core; locating the mold core and the preform disposedthereon in a container mold having an internal surface; stretching thepreform into conformity with the internal surface of the mold cavity byfilling an interior of the preform with the liquid through a channeldefined by the mold core, pressure of the liquid entering the preformthrough the mold core causing the preform to expand.

In some embodiments, the locating and the stretching is performed beforethe preform has cooled to a threshold temperature.

As such, in accordance with yet another broad aspect of the presenttechnology, there is provided an apparatus for simultaneously formingand filling a final-shaped container from a preform using a liquid, theliquid being a product to be contained in the final-shaped container.The apparatus comprises a mold cavity for forming the final-shapedcontainer from the preform; a stretch rod for stretching the preformmovable between at least a retracted position outside the mold cavity toan advanced position within the mold cavity, a lower portion of thestretch rod being configured for sealably connecting with an interiorsurface of the preform to at least partially isolate a gate portion ofthe preform; and a nozzle for sealably connecting with an opening of thepreform, the nozzle including: a channel fluidly communicating with aninterior of the preform for transmission of the liquid to expand thepreform into conformity with the mold cavity and form the containertherein, the channel being further configured to receive the stretch rodtherethrough.

In some embodiments, the channel further fluidly communicates with apressurized air source for performing a preliminary stretch of thepreform by blow molding.

In some embodiments, the stretch rod comprises a deformable memberconfigured to at least partially isolate the gate portion of the preformfrom the liquid when extended, the liquid causing the deformable memberto extend out from the stretch rod to contact the interior surface ofthe preform to form a temporary seal to at least partially isolate thegate portion from the liquid when filling an interior of the preformwith the liquid through the nozzle.

In some embodiments, the deformable member is made at least in part froma thermally isolating material.

In some embodiments, the deformable member is made at least on part froma material having low thermal conductivity.

In some embodiments, the material having low thermal conductivity is oneof a polymer and a rubber.

In some embodiments, the stretch rod comprises ancontrollably-extendible sealing member for sealably connecting the lowerportion of the stretch rod with the interior surface of the preform, thecontrollably-extendible sealing member selectively and at leastpartially isolating the gate portion of the preform from the liquid whenextended; and the apparatus further comprises an actuator for extendingthe controllably-extendible sealing member.

In some embodiments, the controllably-extendible sealing member is madeat least in part from a thermally isolating material.

As such, in accordance with yet another broad aspect of the presenttechnology, there is provided an apparatus for simultaneously formingand filling a final-shaped container from a preform using a liquid, theliquid being a product to be contained in the final-shaped container.The apparatus comprises a mold cavity for forming the final-shapedcontainer from the preform; a stretch rod for stretching the preformmovable between at least a retracted position outside the mold cavity toan advanced position within the mold cavity, the stretch rod including:a selectively heatable tip; and a nozzle for sealably connecting with anopening of the preform, the nozzle including: a channel fluidlycommunicating with an interior of the preform for transmission of theliquid to expand the preform into conformity with the mold cavity andform the container therein, the channel being further configured toreceive the stretch rod therethrough.

In some embodiments, the selectively heatable tip comprises an internalresistor for causing at least a lower portion of the stretch rod toheat.

In some embodiments, the stretch rod defines at least one channelfluidly communicating with an interior of the preform and a pressurizedair source, the stretch rod being configured for partial blow-molding ofthe preform prior to transmission of the liquid.

As such, in accordance with yet another broad aspect of the presenttechnology, there is provided a preform suitable for subsequentsimultaneous forming and filling of a final-shaped container using aliquid, the liquid being a product to be contained in the final-shapedcontainer. The preform comprises a neck portion; a gate portion; and abody portion extending between the neck portion and the gate portion,the neck portion, the gate portion and the body portion defining aninner surface of the preform, a portion of the inner surface extendinginward, the portion being adapted for sealably connecting with a stretchrod inserted therein for isolating at least the gate portion from theliquid during the subsequent simultaneous forming and filling of thefinal-shaped container.

In some embodiments, the portion of the inner surface is a protrusionextending inward from the inner surface, the protrusion being configuredfor creating a seal with a stretching rod inserted into the preformduring the subsequent simultaneous forming and filling; and theprotrusion is located near a boundary between the gate portion and thebody portion.

In some embodiments, the protrusion is located along one of the boundarybetween the body portion and the gate portion, and a region of the innersurface extending from the boundary towards a gate nub portion of thegate portion.

As such, in accordance with yet another broad aspect of the presenttechnology, there is provided a system for simultaneously forming andfilling a final-shaped container from a preform using a liquid, theliquid being a product to be contained in the final-shaped container.The system comprises the preform comprising a neck portion, a gateportion, and a body portion extending between the neck portion and thegate portion, the neck portion, the gate portion and the body portiondefining an inner surface of the preform; and a stretch rod forstretching the preform, the stretch rod movable between at least aretracted position outside the mold cavity to an advanced positionwithin the mold cavity, a portion of the inner surface of the preformextending inward, the portion being adapted for sealably connecting withthe stretch rod inserted therein for isolating at least the gate portionfrom the liquid during the simultaneous forming and filling of thefinal-shaped container.

As such, in accordance with yet another broad aspect of the presenttechnology, there is provided a preform suitable for subsequentsimultaneous forming and filling of a final-shaped container using aliquid, the liquid being a product to be contained in the final-shapedcontainer. The preform comprises a neck portion; a gate portion; and abody portion extending between the neck portion and the gate portion, atleast the gate portion including: an inner exterior layer and an outerexterior layer comprising a first polymeric material; and a core layerof a second polymeric material disposed between at least a portion ofthe inner exterior layer and the outer exterior layer, at least one ofthe inner exterior layer, the outer exterior layer, and the core layercomprising a thermally isolating material configured to slow a thermalcooling rate of the gate portion.

In some embodiments, each layer of the gate portion comprises thethermally isolating material configured to slow the thermal cooling rateof the gate portion.

As such, in accordance with yet another broad aspect of the presenttechnology, a preform suitable for subsequent simultaneous forming andfilling of a final-shaped container using a liquid, the liquid being aproduct to be contained in the final-shaped container. The preformcomprises a neck portion; a gate portion; and a body portion extendingbetween the neck portion and the gate portion, at least the gate portionincluding: an inner exterior layer and an outer exterior layercomprising a first polymeric material; and a core layer of a secondpolymeric material disposed between at least a portion of the innerexterior layer and the outer exterior layer, at least one of the innerexterior layer, the outer exterior layer, and the core layer comprisinga thermally absorptive material configured to increase a thermal heatingrate of the gate portion.

In some embodiments, the additive is a colorant.

In some embodiments, the additive is a fast reheat additive.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present technology, as well as otheraspects and further features thereof, reference is made to the followingdescription which is to be used in conjunction with the accompanyingdrawings, where:

FIGS. 1A-1F schematically depict steps in forming a final-shapedcontainer using a liquid product as known in the prior art.

FIG. 2 is a cross-sectional view of a preform as known in the prior art.

FIG. 3 depicts a side, cross-sectional schematic view of a preform and aforming machine according to one non-limiting embodiment of the presenttechnology.

FIGS. 4A-4B depict side, cross-sectional schematic views of the preformand a stretch rod of the forming machine of FIG. 3 .

FIGS. 5A-5B depict side, cross-sectional schematic views of the preformand a stretch rod in accordance with another non-limiting embodiment ofthe present technology.

FIG. 6 depicts a side, cross-sectional schematic view of a preform inaccordance with another non-limiting embodiment of the presenttechnology for use with the stretch rod of FIG. 3 .

FIGS. 7A-7B depict side, cross-sectional schematic views of the preformof and a stretch rod of the forming machine of FIG. 3 in accordance withanother non-limiting embodiment of the present technology.

FIG. 8 depicts a side, cross-sectional schematic view of the preform ofFIG. 2 and a forming machine according to another non-limitingembodiment of the present technology.

FIGS. 9A-9B depict side, cross-sectional schematic views of the preformand the stretch rod of the forming machine of FIG. 8 .

FIGS. 10 and 11 depict side, cross-sectional schematic views of thepreform of FIG. 2 and a stretch rod in accordance with anothernon-limiting embodiment of the present technology.

FIG. 12 depicts a side, cross-sectional schematic view of the preform ofFIG. 2 and a forming machine according to another non-limitingembodiment of the present technology.

FIG. 13 is a schematic flow chart of a non-limiting embodiment of amethod according to the present technology.

FIG. 14A is a side, cross-sectional schematic view of a preformaccording to another non-limiting embodiment of the present technology.

FIG. 14B is a side, cross-sectional schematic view of a preformaccording to yet another non-limiting embodiment of the presenttechnology.

FIG. 15 is a side, cross-sectional schematic view of a preform accordingto yet another non-limiting embodiment of the present technology.

FIGS. 16 to 18 depict cross-sectional views of a portion of a moldingstack used in a molding machine, the molding stack implemented accordingto yet another non-limiting embodiment of the present technology.

FIG. 19 schematically depicts a process of creating final-shapedcontainers according to yet another non-limiting embodiment of thepresent technology.

FIG. 20 depicts a non-limiting embodiment of an end-of-arm tool for usedfor implementing the process of FIG. 19 .

FIG. 21 is a schematic flow chart of another non-limiting embodiment ofa method according to the present technology.

FIG. 22 schematically depicts an injection molding system that can beadapted to implement non-limiting embodiments of the present technology.

The drawings are not necessarily to scale and may be illustrated byphantom lines, diagrammatic representations and fragmentary views. Incertain instances, details that are not necessary for an understandingof the embodiments or that render other details difficult to perceivemay have been omitted.

DETAILED DESCRIPTION

Reference will now be made in detail to various non-limiting embodimentsfor preforms and liquid forming systems for reconfiguring the preform tothe final-shaped container. It should be understood that othernon-limiting implementations, modifications and equivalents will beevident to one of ordinary skill in the art in view of the non-limitingimplementations disclosed herein and that these variants should beconsidered to be within scope of the appended claims. Furthermore, itwill be recognized by one of ordinary skill in the art that certainstructural and operational details of the non-limiting implementationsdiscussed hereafter may be modified or omitted altogether (i.e.non-essential). In other instances, well known methods, procedures, andcomponents have not been described in detail.

It is to be further expressly understood that the preforms and liquidforming systems and its components are depicted merely as anillustrative implementation of the present technology. Thus, thedescription thereof that follows is intended to be only a description ofillustrative examples of the present technology. This description is notintended to define the scope or set forth the bounds of the presenttechnology. In some cases, what are believed to be helpful examples ofmodifications to the preforms and liquid forming systems and/or itscomponents may also be set forth below. This is done merely as an aid tounderstanding, and, again, not to define the scope or set forth thebounds of the present technology. These modifications are not anexhaustive list, and, as a person skilled in the art would understand,other modifications are likely possible.

Further, where this has not been done (i.e. where no examples ofmodifications have been set forth), it should not be interpreted that nomodifications are possible and/or that what is described is the solemanner of implementing that element of the present technology. As aperson skilled in the art would understand, this is likely not the case.In addition it is to be understood that the preforms and liquid formingsystems and/or its components may provide in certain instances simpleembodiments of the present technology, and that where such is the casethey have been presented in this manner as an aid to understanding. Aspersons skilled in the art would understand, various implementations ofthe present technology may be of a greater complexity. Furthermore,where specific details of the different implementations are presentedwith reference to discrete embodiments, a person skilled in the art isexpected to combine specific implementational details of one discreteembodiment with specific implementational details of another discreteembodiment, even though such a combination may not be expresslydisclosed herein below.

Molding System

With reference to FIG. 22 , there is depicted a non-limiting embodimentof a molding system 100 which can be adapted to implement embodiments ofthe present technology. For illustration purposes only, it shall beassumed that the molding system 100 comprises an injection moldingsystem for processing molding material, such as PET for example, to makepreforms that are subsequently molded into final-shaped containers.However, it should be understood that in alternative non-limitingembodiments, the molding system 100 may comprise other types of moldingsystems, such as, but not limited to, compression molding systems,compression injection molding systems, transfer molding systems, metalmolding systems and the like.

It should be further understood that embodiments of the presenttechnology are applicable to the molding system 100 incorporating anymulti-cavitation mold for producing any type of preforms.

In the non-limiting embodiment of FIG. 22 , the molding system 100comprises a fixed platen 102 and a movable platen 104. In someembodiments of the present technology, the molding system 100 mayinclude a third non-movable platen (not depicted). Alternatively oradditionally, the molding system may include turret blocks, rotatingcubes, turning tables and the like (all not depicted but known to thoseof skill in the art).

The molding system 100 further comprises an injection unit 106 forplasticizing and injection of molding material. The injection unit 106can be implemented as a single stage or a two-stage injection unit.

In operation, the movable platen 104 is moved towards and away from thefixed platen 102 by means of stroke cylinders (not shown) or any othersuitable means. Clamp force (also referred to as closure or mold closuretonnage) can be developed within the molding system 100, for example, byusing tie bars 108, 110 (typically, four tie bars 108, 110 are presentin the molding system 100) and a tie-bar clamping mechanism 112, as wellas (typically) an associated hydraulic system (not depicted) that isusually associated with the tie-bar clamping mechanism 112. It will beappreciated that clamp tonnage can be generated using alternative means,such as, for example, using a column-based clamping mechanism, atoggle-clamp arrangement (not depicted) or the like.

A first mold half 114 can be associated with the fixed platen 102 and asecond mold half 116 can be associated with the movable platen 104. Inthe non-limiting embodiment of FIG. 22 , the first mold half 114comprises one or more mold cavities 118. As will be appreciated by thoseof skill in the art, the one or more mold cavities 118 may be formed byusing suitable mold inserts (such as a cavity insert, a gate insert andthe like) or any other suitable means. As such, the first mold half 114can be generally thought of as a “mold cavity half”.

The second mold half 116 comprises one or more mold cores 120complementary to the one or more mold cavities 118. As will beappreciated by those of skill in the art, the one or more mold cores 120may be formed by using suitable mold inserts or any other suitablemeans. As such, the second mold half 116 can be generally thought of asa “mold core half”. Even though not depicted in FIG. 22 , the first moldhalf 114 may be further associated with a melt distribution network,commonly known as a hot runner, for distributing molding material fromthe injection unit 106 to each of the one or more mold cavities 118.Also, in those embodiments where the molding system 100 is configured toproduce preforms, the second mold half 116 can be provided with neckrings (not depicted).

The first mold half 114 can be coupled to the fixed platen 102 by anysuitable means, such as a suitable fastener (not depicted) or the like.The second mold half 116 can be coupled to the movable platen 104 by anysuitable means, such as a suitable fastener (not depicted) or the like.It should be understood that in an alternative non-limiting embodimentof the present technology, the position of the first mold half 114 andthe second mold half 116 can be reversed and, as such, the first moldhalf 114 can be associated with the movable platen 104 and the secondmold half 116 can be associated with the fixed platen 102.

In an alternative non-limiting embodiment of the present technology, thefixed platen 102 need not be stationary and may be movable in relationto other components of the molding system 100.

FIG. 22 depicts the first mold half 114 and the second mold half 116 ina so-called “mold open position” where the movable platen 104 ispositioned generally away from the fixed platen 102 and, accordingly,the first mold half 114 is positioned generally away from the secondmold half 116. For example, in the mold open position, a molded article(not depicted) can be removed from the first mold half 114 and/or thesecond mold half 116. In a so-called “mold closed position” (notdepicted), the first mold half 114 and the second mold half 116 areurged together (by means of movement of the movable platen 104 towardsthe fixed platen 102) and cooperate to define (at least in part) amolding cavity (not depicted) into which the molten plastic (or othersuitable molding material) can be injected, as is known to those ofskill in the art.

It should be appreciated that one of the first mold half 114 and thesecond mold half 116 can be associated with a number of additional moldelements, such as for example, one or more leader pins (not depicted)and one or more leader bushings (not depicted), the one or more leaderpins cooperating with one more leader bushings to assist in alignment ofthe first mold half 114 with the second mold half 116 in the mold closedposition, as is known to those of skill in the art.

The molding system 100 can further comprise a robot 122 (also referredto as an “end of arm tool”) operatively coupled to the fixed platen 102.Those skilled in the art will readily appreciate how the robot 122 canbe operatively coupled to the fixed platen 102 and, as such, it will notbe described here in any detail. The robot 122 comprises a mountingstructure 124, an actuating arm 126 coupled to the mounting structure124 and a take-off plate 128 coupled to the actuating arm 126. Thetake-off plate 128 comprises a plurality of molded article receptacles130.

Generally speaking, the purpose of the plurality of molded articlereceptacles 130 is to remove molded articles from the one or more moldcores 120 (or the one or more mold cavities 118) and/or to implementpost mold cooling of the molded articles. In the non-limiting exampleillustrated herein, the plurality of molded article receptacles 130comprises a plurality of cooling tubes for receiving a plurality ofmolded preforms. However, it should be expressly understood that theplurality of molded article receptacles 130 may have otherconfigurations. The exact number of the plurality of molded articlereceptacles 130 is not particularly limited.

Schematically depicted in FIG. 22 is the robot 122 of a side-entry type.However, it should be understood that in alternative non-limitingembodiments of the present technology, the robot 122 can be of atop-entry type. It should also be expressly understood that the term“robot” is meant to encompass structures that perform a singleoperation, as well as structures that perform multiple operations.

The molding system 100 further comprises a post-mold treatment device132 operatively coupled to the movable platen 104. Those skilled in theart will readily appreciate how the post-mold treatment device 132 canbe operatively coupled to the movable platen 104 and, as such, it willnot be described here in any detail. The post-mold treatment device 132comprises a mounting structure 134 used for coupling the post-moldtreatment device 132 to the movable platen 104. The post-mold treatmentdevice 132 further comprises a plenum 129 coupled to the mountingstructure 134. Coupled to the plenum 129 is a plurality of treatmentpins 133. The number of treatment pins within the plurality of treatmentpins 133 generally corresponds to the number of receptacles within theplurality of molded article receptacles 130.

The molding system 100 further comprises a controller 140, thecontroller including a human-machine interface (not separately numbered)or an HMI, for short. Generally speaking, the controller 140 isconfigured to control one or more operations of the molding system 100.The HMI of the controller 140 can be implemented in any suitableinterface. As an example, the HMI of the controller 140 can beimplemented in a multi-functional touch screen. An example of the HMIthat can be used for implementing non-limiting embodiments of thepresent technology is disclosed in co-owned U.S. Pat. No. 6,684,264,content of which is incorporated herein by reference, in its entirety.

Those skilled in the art will appreciate that the controller 140 may beimplemented using pre-programmed hardware or firmware elements (e.g.,application specific integrated circuits (ASICs), electrically erasableprogrammable read-only memories (EEPROMs), etc.), or other relatedcomponents. In other embodiments, the functionality of the controller140 may be achieved using a processor that has access to a code memory(not shown) which stores computer-readable program code for operation ofthe computing apparatus, in which case the computer-readable programcode could be stored on a medium which is fixed, tangible and readabledirectly by the various network entities, (e.g., removable diskette,CD-ROM, ROM, fixed disk, USB drive), or the computer-readable programcode could be stored remotely but transmittable to the controller 140via a modem or other interface device (e.g., a communications adapter)connected to a network (including, without limitation, the Internet)over a transmission medium, which may be either a non-wireless medium(e.g., optical or analog communications lines) or a wireless medium(e.g., microwave, infrared or other transmission schemes) or acombination thereof.

In alternative non-limiting embodiments of the present technology, theHMI does not have to be physically attached to the controller 140. As amatter of fact, the HMI for the controller 140 can be implemented as aseparate device. In some embodiments, the HMI can be implemented as awireless communication device (such as a smartphone, for example) thatis “paired” or otherwise communicatively coupled to the controller 140.

Overview of the Liquid Forming Process

The present technology includes various improvements to methods,apparatuses, and systems for forming final-shaped containers frompreforms using a liquid destined to be contained in the final-shapedcontainer. In order to better understand the various improvements thatcan be achieved by implementing the non-limiting embodiments of thepresent technology, a generic process of liquid forming of thefinal-shaped container will now be described with reference to FIGS. 1Aand 1B.

The process starts with a preform 50, such as one produced by themolding system 100. The various implementations of the preform 50 willbe described in more detail below. The first step includes heating thepreform 50 in a heater 21, in order to bring the preform 50 to atemperature where the preform 50 will deform, as is the case whenblow-molding. Next, the heated preform 50 is placed in a mold 26 (whichcan also be thought as a “forming mold”), whose interior surfacecorresponds to the desired final shape of the final-shaped container tobe molded. The mold 26 is implemented as a split mold made of threeportions 23 (two mold halves and a base portion), which are configuredto be opened and closed (as will be explained in greater detail hereinbelow).

A nozzle 30 is inserted into the preform 50, such that a portion of thenozzle 30 is sealably connected with an opening of the preform 50.Broadly speaking, the nozzle 30 comprises a channel (not depicted)fluidly communicating with an interior of the preform 50 fortransmission of the liquid to expand the preform 50 into conformity withthe mold 26 and form the container therein. The liquid is supplied via acoupling 32 from a liquid reservoir (not separately numbered).

In some processes, the channel is configured to receive a stretch rod 40therethrough. In other words, the nozzle 30 is configured to stretch thepreform 50 into conformity with the internal surface of the formingcavity of the mold 26:

-   -   by filling an interior of the preform with the liquid through        the nozzle 30, pressure of the liquid entering the preform 50        causing the preform 50 to expand; and    -   additionally in some embodiments of the present technology, the        stretching is assisted by the stretch rod 40.

Once the preform 50 is stretched into the final-shaped container 15 (seeFIG. 1B), it is also effectively filled with the liquid that is to becontained in the final-shaped container 15. In this way, the processincludes fewer steps in comparison to, for example, blow molding, whereforming the final-shaped container 15 and filling the final-shapedcontainer 15 are performed sequentially and not simultaneously. At thispoint the three mold portions 23 of the mold 26 are separated into amold opened configuration such that the final-shaped container 15 can beremoved therefrom.

The final-shaped container 15 is also capped with a closure 17, theclosure being structured and configured based on the liquid contained inthe final-shaped container 15. As is known, closure 17 used fornon-carbonated beverage is implemented differently form the closure usedfor a carbonated beverage or a hot fill beverage (such as a drinkableyogurt, for example).

In order to implement the non-limiting embodiments of the presenttechnology, the liquid that is used for liquid forming is a product tobe contained in the final-shaped container. In some non-limitingembodiments, the product is a beverage (such as still water beverage,juice, or the like). In other embodiments, the product can be adrinkable yogurt. In other non-limiting embodiments of the presenttechnology, the product is not for human consumption and can be, forexample, liquid glue, paint, shampoo or the like.

Description of a Preform

With reference to FIG. 2 , there is depicted a conventional preform 50,produced by the molding system 100, as an example. The prior art preform50 is described herein to provide a general structure of a moldedarticle suitable for subsequent liquid molding; specifics of moldedarticles according to the present technology will be described in moredetail below. It should be recalled that the molding system 100 can beimplemented as any type of molding machine and, therefore, it iscontemplated that the preforms 50 could be produced any type of themolding system 100 (such as injection molding machine, injectioncompression molding machine, transfer molding and the like).

The preform 50 consists of a neck portion 32, a gate portion 36 and abody portion 34 extending between the neck portion 32 and the gateportion 36. The gate portion 36 is associated with a substantiallyspherical shape that terminates in a vestige portion 38. Naturally, thegate portion 36 can be executed in another form-factor (such assubstantially conical, frusto-conical or the like). The body portion 34of the preform 50 can be of a single layer or of a multi-layerstructure. In the illustration of FIG. 2 , the preform 50 is depicted ofa multi-layer configuration, namely of a three layer configuration. Thethree layer configuration of the preform 50 is presented as one exampleimplementation of a preform. Various aspects of the present technologymay be applicable to multi-layer configurations of the preform 50, whileother aspects may be more applicable to preforms constructed from two orone layers of material.

On exterior sides, the body portion 34 has an outer exterior skin layer20 and an inner exterior skin layer 25. The skin layers 20, 25 can bemade of various materials. For example, in multilayer preforms 50 formaking beverage containers, the skin layers 20, 25 are made of virginpolyethylene terephthalate (PET), which is approved by the FDA for usein contact with foodstuffs. It is contemplated that the skin layers 20,25 could be made of various other materials, including any appropriatepolymer resins and thermoplastics, as will be appreciated by thoseskilled in the art.

The skin layers 20, 25 surround a core layer 39. The core layer 39 isgenerally made of a different material, or a different state of the samematerial, than the skin layers 20, 25. At a top end of the preform 50,the core layer 39 begins at a leading edge 42. At the gate portion ofthe preform 50, the core layer 39 terminates at a trailing edge 44. Itis contemplated that, in some alternative implementations of the preform50, the core layer 39 may extend through the gate portion 36 to form aclosed dome formation.

As will be described in part below, the core layer 39 is used to impartdifferent properties to the preforms 50. The core layer 39, in someembodiments, can act as a barrier layer in the eventual blow-moldedcontainer blown from the preform 50. In such cases, the barrier layercan help to prevent transmission of, for example, oxygen or light intoan interior of the blow-molded container. The core layer 39 can also bemade from any one of various appropriate thermoplastics and polymerresins as will be appreciated by those skilled in the art. It iscontemplated that the core layer 39 could also contain variousadditives, coloring, or property adjusting agents to affect differentproperties of the preform 50.

Description of a Preform and a Stretch Rod (Forming a Seal)

With reference to FIGS. 3 to 4B, an apparatus 200, a method 500, and aprocess for simultaneous forming and filling a final-shaped containeraccording to some non-limiting embodiments will now be described. Theapparatus 200 can also be referred to herein below as a “formingapparatus”. a “forming machine” or a “forming system”.

FIG. 3 depicts a mold cavity 240 having the internal surface 242. Themold cavity 240 is also referred as the “container cavity” and is shapedto the desired shape of the final-shaped container 15. The mold cavity240 is implemented as a split mold in a sense that it is made of twocomplementary halves (not separately numbered), which are actuatabletogether (into a closed configuration of FIG. 3 ) and apart (into anopen configuration, which is not depicted).

Positioned within the mold cavity 240 is a preform 300, the preform 300having an internal surface 302 (also sometimes called an internal skin302). The preform 300 is depicted in the just molded state, prior to thepreform being shaped into the final-shaped container 15.

There is also depicted a nozzle assembly 220 configured to implementnon-limiting embodiments of the present technology. The nozzle assembly220 comprises a TSS seal member 222 for sealing with a Top SealingSurface (TSS) of the preform 300, which is not separately numbered. Thenozzle assembly 220 defines a channel 224 fluidly coupled to a liquidreservoir 250 for receiving liquid therefrom. In the in-use position,the channel 224 is also fluidly communicating with an interior of thepreform 300, into which the nozzle assembly 220 is positioned. Thechannel 224 is configured to receive a stretch rod 210 therethrough.

Within the depicted embodiment, a portion of the preform geometry andthe stretch rod 210 are configured to cooperate to least partiallyisolate a gate portion of the preform 300 from contacting the liquidthat is used for liquid forming. With specific reference to FIG. 4A, thepreform 300 comprises a lower portion 336. The lower portion 336generally corresponds to a portion of the preform defined by a gateinsert of the molding system 100 (in which case the lower portion 336can, but does not have to, correspond to the gate portion of the preform300). To that end the lower portion 336 starts at the gate nub (notseparately numbered) and terminates at a transition point between thegate portion and the body portion.

In the illustrated embodiment, the lower portion 336 is associated witha smaller inner diameter compared to the inner diameter of the bodyportion of the preform 300.

The inner diameter of the lower portion 336 is configured to cooperatewith a lower portion 212 of the stretch rod 210 to seal the lowerportion 336 of the preform 300 from being in contact with the liquidduring certain portions of the liquid forming process of the preform 300into the final-shaped container. In some embodiments of the presenttechnology, the inner diameter of the lower portion 336 and the lowerportion 212 of the stretch rod 210 are dimensioned in a size-on-sizerelationship (as is best seen in FIG. 4B).

It is noted that the seal described above between the preform inner skinand the stretch rod 210 does not need to be water tight (i.e. someleakage may occur). The seal is above all configured to retardpressurization/cooling of the lower portion 336. As such the seal maythought as an ‘obstruction’ that isolates the downstream portion frompremature pressurization and/or cooling.

In some embodiments of the present technology, the stretch rod 210 canbe provided with an additional sealing member (such as an O-ring or thelike) to assist in sealing.

It is noted that the exact placement of the sealing/obstructing is notparticularly limited. In the depicted embodiments, it is placed at atransition between the gate portion and the body portion of the preform300 (as well as along the entirety of the lower portion 336), but thisdoes not need to be so in every alternative embodiment of the presenttechnology. The seal location may be defined by a transition to athickened region of the base/body, wherein the additional material,relative to the remainder of the preform 300 for liquid forming, ensuresthat a base of the final-shaped container is adequately formed (i.e. isnot too thin or too quickly cooled to be fully formed).

In accordance with some non-limiting embodiments of the presenttechnology, the process of simultaneous forming and filling afinal-shaped container can be implemented as follows. With reference toFIG. 13 , there is depicted a flow chart of a method 500 implemented inaccordance with some non-limiting embodiments of the present technology.The method 500 can be implemented under control of the controller 140.

Step 510

Locating the preform 300 in the mold cavity 240 having the internalsurface 242.

Step 520

Sealably connecting the nozzle assembly 220 onto an opening of thepreform 300.

Step 530

Inserting the stretch rod 210 through the nozzle assembly 220 into theopening of the preform 300, at least the lower portion 212 of thestretch rod 210 sealably connecting with the internal surface 302 of thepreform 300 to at least partially isolate the lower portion 336.

Step 540

Stretching the preform 300 into conformity with the internal surface 242of the mold cavity 240 by:

-   -   at substep 550—filling an interior of the preform 300 with the        liquid through the nozzle assembly 220, and    -   at substep 560—extending the stretch rod 210 farther into the        lower portion 336.

In some embodiments of the present technology, the substep 550 at leastpartially overlaps with the substep 560. In some embodiments of thepresent technology, the substep 560 commences at a pre-determined pointof time after the step 550 commences.

With reference to FIGS. 5A-5B, another embodiment of a stretch rod 210′will be described. In accordance with these alternative embodiments, thestretch rod 210′ comprises scalloped geometry at a lower extreme of thelower portion 212′ thereof. As is better shown in FIG. 5B, the scallopedgeometry of the stretch rod 210′ cooperates with the inner radius of thelower portion 336 of the preform 330 to provide the sealing to isolatethe gate portion of the preform 330 from the liquid.

Therefore, by considering embodiments of FIGS. 4A-4B and FIGS. 5A-5B, itcan be said that the geometry of at least one of the lower portion 336of the preform 330 and the stretch rod 210, 210′ are configured toisolate the gate portion of the preform 330 from the liquid. Theillustrated geometries of FIGS. 4A-5B as simply presented asnon-limiting examples, and are not intended to limit the possiblegeometries that fall within the scope of the present technology. Variousshapes of the stretch rod 210 and the preform 300 are contemplated. Asillustrated, a portion of the inner surface 302 extends inward andconfigured for sealably connecting with the stretch rod 210, 210′.

In accordance with yet another non-limiting embodiment of the presenttechnology illustrated in FIG. 6 , a preform 300′ can be used in placeof the preform 300.

The preform 300′ includes a protrusion 339 defined in a lower portion336′ for forming a seal with the stretch rod 210. The protrusion 339extends inward from the internal surface 302, the protrusion beingconfigured for creating a seal with a stretch rod 210 inserted into thepreform 300 during the simultaneous forming and filling. The illustratedprotrusion 339 is simply an example of a form that the protrusion 339could take. It is contemplated that the protrusion 339 could be larger,smaller, or differently shaped. The specific implementation of the shapeof the protrusion 339 will depend inter alia on the size of the preform300′, the pressure of the liquid used for liquid forming, the size ofthe final-shaped container and the like.

In accordance with the illustrated embodiment of the present technology,the protrusion 339 is located near a boundary between the gate portionand the body portion of the preform 300. However, in alternativenon-limiting embodiments of the present technology, the stretch rod 210could include a protrusion similar to the protrusion 339, located toalign with one of: the boundary between the body portion and the gateportion, and a region of the internal surface 302 extending from theboundary towards a gate nub portion of the lower portion 336′.

Description of a Stretch Rod with a Heatable Tip

With reference to FIGS. 7A and 7B, another embodiment of a stretch rod210″ will be described. The stretch rod 210″ can be used in place of thestretch rod 210, but remaining portions of the apparatus 200 remainunchanged and will not be described again here.

The stretch rod 210″ can be used in conjunction with the preform 300,described above. The stretch rod 210″ includes a heater 214 disposed ina tip 212″. The tip 212″ sealingly engages with internal surface 302(see, for example, FIG. 7B). The heater 214 (that defines a selectivelyheatable tip of the stretch rod 210″) comprises an internal resistor forcausing at least a lower portion of the stretch rod 210″ to heat. Byheating the lower portion 336 of the preform 300, the stretch rod 210″can aid in preventing the lower portion 336 from pressurization and/orcooling prematurely.

It is also contemplated that the stretch rod 210″ could be used with thetraditional preform 50, where the stretch rod 210″ could also includeadditional structures for creating a seal with the preform 50.

In some non-limiting embodiments of the present technology, the stretchrod 210, 210″ can define at least one channel fluidly communicating withan interior of the preform and a pressurized air source, the stretch rod210, 210″ being configured for partial blow-molding of the preform priorto transmission of the liquid.

Description of a Stretch Rod with a Deformable Member and a Method UsingSame

With reference to FIGS. 8 to 9B, another non-limiting embodiments of anapparatus 400 for simultaneously forming and filling the final-shapedcontainer 15 from the preform 50 using the liquid product will now bedescribed. It is contemplated that the preform 300 could equally by usedwith the apparatus 400. It is noted that other preform configurationscan also be used.

In the embodiment illustrated, there is a stretch rod 410 including adeformable member 420. Broadly speaking, the deformable member 420 isconfigured to at least partially isolate the gate portion of the preform50 from the liquid during appropriate portions of the liquid forming ofthe preform 50 into the final-shaped container 15. Broadly speaking, thedeformable member 420 can be made at least in part from a thermallyisolating material. In other words, the deformable member 420 can bemade at least on part from a material having low thermal conductivity.As an example, the deformable member 420 can be from a polymer orrubber.

In the depicted illustration, the deformable member is implemented as arubber cup 420 disposed about a lower portion 412 of the stretch rod410. The rubber cup 420 extends radially from the lower portion 412 ofthe stretch rod 410.

The rubber cup 420 is depicted in a collapsed (or disengaged)configuration in FIG. 8 and FIG. 9A and in an extended (or engaged)configuration in FIG. 9B. In the disengaged configuration, thedeformable member is dimensioned to pass through a neck opening of thepreform 50 (from outside of the preform 50, through the opening in theneck of the preform 50 and into the body of the preform 50). In theengaged configuration, the rubber cup 420 is configured to engage theinner surface of the preform 50 to at least partially isolate the gateportion 36 of the preform 50 from the liquid during appropriate portionsof the liquid forming of the preform 50 into the final shaped-container15.

In some non-limiting embodiments of the present technology, theactuation of the rubber cup 420 between the collapsed (or disengaged)configuration in FIG. 9A and the extended (or engaged) configuration inFIG. 9B can be implemented as follows.

When filling an interior of the preform 50 with the liquid through thenozzle assembly 220, the liquid causes the deformable member 420 toextend out from the stretch rod 410 to contact the interior surface ofthe preform 50 to form a temporary seal to at least partially isolatethe gate portion 36 from the liquid.

The rubber cup 420 is repositionable, between the disengagedconfiguration and the engaged configuration, by the pressure of theliquid filling the interior of the preform 50. The return of the rubbercup 420 from the engaged configuration to the disengaged configurationis executed in response to a decrease of the pressure of the liquidfilling the interior of the preform.

It is noted that in alternative non-limiting embodiments of the presenttechnology, the deformable member 420 can be implemented in any othershape, such as a collapsible umbrella shape, as an example. Thedeformable member 420 can be made of any suitable material, such as anelastomeric material. One material consideration when selecting thematerial for the deformable member 420 is flexibility and pressureresistance. Alternatively, the deformable member 420 can be made of, orinclude, metal components that “wing out” from the collapsedconfiguration to the extended configuration.

Alternative Implementation—Controllably-Extendible Sealing Member

With reference to FIGS. 10 and 11 , an apparatus 400′ for simultaneouslyforming and filling the final-shaped container 15 from the preform 50using the liquid product will now be described. It is again contemplatedthat the preform 300, as well as other preform configurations, couldequally by used with the apparatus 400′.

The apparatus 400′ comprises a stretch rod 410′. The stretch rod 410′comprises a controllably-extendible sealing member 420′ disposed arounda lower portion thereof. The controllably-extendible sealing member 420′is another embodiment for implementing the sealing member 420. Thus, theoperation of the controllably-extendible sealing member 420′ and thestretch rod 410′ is substantially similar to that of the stretch rod410, but for the specific differences described herein below. Thecontrollably-extendible sealing member 420′ can be thought of as an“actively controllable” controllably-extendible sealing member 420′ inthe sense that it is controlled by a controller for controlledreconfiguration between the disengaged and the engaged configurations.

The controllably-extendible sealing member 420′ is configured toselectively and at least partially isolate the gate portion of thepreform from the liquid. To that end, the controllably-extendiblesealing member 420′ is configured to be actuated from the collapsedconfiguration of FIG. 10 to an engaged configuration of FIG. 11 , wherethe controllably-extendible sealing member 420′ contacts the interiorsurface of the preform 50 to form a temporary seal for at leastpartially isolating the gate portion 36. Broadly speaking, as with thedeformable member 420, the controllably-extendible sealing member 420′can be made at least in part from a thermally isolating material. Othermaterials can of course also be used to implement thecontrollably-extendible sealing member 420′.

In embodiments of the present technology, the controllably-extendiblesealing member 420′ is actuated by the controller 140 operativelyconnected to the stretch rod 410′ via an electric coupling 425. It iscontemplated that in some embodiments the controllably-extendiblesealing member 420′ could be actuated by a rod-in-rod mechanical controlsystem.

Alternative Implementation—Controllably-Inflating Sealing Member

With reference to FIG. 12 , an apparatus 400″ for simultaneously formingand filling the final-shaped container 15 from the preform 50 using theliquid product will now be described. It is again contemplated that thepreform 300, as well as other preform configurations, could equally byused with the apparatus 400″.

The apparatus 400″ comprises a stretch rod 410″. The stretch rod 410″comprises a controllably-deformable sealing member 420″ disposed arounda lower portion thereof. The controllably-deformable sealing member 420″is another embodiment for implementing the sealing member 420. Thus, theoperation of the controllably-deformable sealing member 420″ and thestretch rod 410″ is substantially similar to that of the stretch rod410, but for the specific differences described herein below. Thecontrollably-deformable sealing member 420″ can be thought of as anactively controllable controllably-deformable sealing member 420″ in thesense that it is controlled by a controller for controlledreconfiguration between the disengaged and the engaged configurations.

The controllably-deformable sealing member 420″ is configured toselectively and at least partially isolate the gate portion of thepreform from the liquid. The controllably-deformable sealing member 420″is specifically a rubber air bladder 420″ disposed about the stretch rod410″ in the illustrated embodiment. In other embodiments, the rubber airbladder 420″ can be made from or include different materials.

To that end, the controllably-deformable sealing member 420″ isconfigured to be actuated from a collapsed configuration (not shown) toan engaged configuration of FIG. 12 , where the controllably-deformablesealing member 420″ contacts the interior surface of the preform 50 toform a temporary seal for at least partially isolating the gate portion36. The sealing member 420″ is actuated from the disengaged (collapsed)configuration to the engaged configuration by inflating the sealingmember 420″ by air injected into the sealing member 420″ throughchannels (not shown) in the stretch rod 410″.

Broadly speaking, as with the deformable member 420, thecontrollably-deformable sealing member 420″ can be made at least in partfrom a thermally isolating material. Other materials can of course alsobe used to implement the controllably-deformable sealing member 420″.

Base Portion Heat Layer

With reference to FIGS. 14A and 14B, additional embodiments of a preform600 and a preform 600′ for use in a system for forming and filling thefinal-shaped container 15 using the liquid product to be contained inthe final-shaped container 15 is depicted. In the embodiment illustratedin FIG. 14A, a core layer 640 is defined only in a gate portion 636 ofthe preform 600. However, it is contemplated that the core layer 640could extend through more or less of the cross section of the preform600. For example, it is contemplated that the core layer 640 couldextend through at least a portion of the body portion of the preform 600and/or through at least a portion of the neck portion of the preform600. It is also contemplated that the preform 600 could includeadditional core layers, such as the core layer 39 of preform 50, inaddition to the core layer 640 depicted in the illustrated embodiment.

The core layer 640 includes a thermally isolating material configured toslow the thermal cooling rate of the gate portion 636. In this way, thegate portion 636 need not necessarily be isolated (but can be) from theliquid during the molding process, but instead the material propertiesof the gate portion 636 itself slows the cooling of the preform 600.

Although illustrated in the core layer 640, it is contemplated that thethermally isolating material could be disposed in the inner or outerlayers of a multilayer preform, such as the preform 50.

As is illustrated in FIG. 14B, another embodiment of the preform 600′includes a gate portion 636′ composed entirely of the thermallyisolating material configured to slow the thermal cooling rate of thegate portion 636′. In this way, the gate portion 636′ need notnecessarily be isolated from the liquid during the molding process, butinstead the material properties of the gate portion 636′ itself slowsthe cooling of the preform 600′.

Base Portion Heat-Absorption Layer

With reference to FIG. 15 , yet another embodiment of a preform 650 foruse in a system for forming and filling the final-shaped container 15using the liquid product to be contained in the final-shaped container15 is depicted.

In the illustrated embodiment, a core layer 690 is included in a gateportion 686 of the preform 650, between layers of a skin material 680.However, it is contemplated that the core layer 690 could extend throughmore or less of the cross section of the preform 650. For example, it iscontemplated that the core layer 690 could extend through at least aportion of the body portion of the preform 650 and/or through at least aportion of the neck portion of the preform 650. It is also contemplatedthat the preform 650 could include additional core layers, such as thecore layer 39 of preform 50, in addition to the core layer 690 depictedin the illustrated embodiment.

In this embodiment, the core layer 690 contains an additive which causesthe core layer 690 to absorb more infrared radiation and/or thermalenergy than the skin material 680, the additive being configured tochange the thermal heating rate of the gate portion 686. In this way,the gate portion 686 need not necessarily be isolated from the liquidduring the molding process. Instead the gate portion 686 itself beginsat a higher temperature than remaining portions of the preform 650, suchthat the gate portion 686 does not cool to a hardening temperature asquickly as the remaining portions of the preform

In some embodiments, the additive could be a colorant which absorbs morethermal energy than the surrounding skin layers. The core layer 690would generally be made of PET, or other known preform materials, withthe colorant additive added thereto. In some cases, the colorant couldaffect the thermal properties of the gate portion 686, while alsoserving to modify the aesthetics of the final molded product.

In some other embodiments, the additive could be a fast reheat additive,which would allow the gate portion 686 to more efficiently absorbthermal energy to increase the heating of the gate portion 686. Somenon-limiting examples of fast reheat additives that could be employedinclude, but are not limited to, Fast Reheat Additive U1 (product ofPolytrade Global GmbH) and ColorMatrix™ Joule™ RHB Fast ReheatDispersions (product of PolyOne Corporation).

In some embodiments, the core layer 690 could include an additive thathas a different absorption spectrum, colored or not, such that the corelayer 690 absorbs more infrared light energy, causing the core layer 690to heat more than the skin material 680 under a same illuminationsource.

Although illustrated in the core layer 690, it is contemplated that thethermally isolating material could be disposed in the inner or outerlayers of a multilayer preform, such as the preform 50.

Core with Channels

With reference to FIGS. 16 to 18 , yet another embodiment of the presenttechnology is depicted, where a molding stack 700 is configured forforming and filling the final-shaped container 15 using the liquidproduct to be contained in the final-shaped container 15.

The overall construction of the molding stack 700 is well known to thoseof skill in the art and as such only those components of the moldingstack 700 that are specifically adapted for implementation of theembodiments of the present technology will be described herein below.

In accordance with these non-limiting embodiments of the presenttechnologies, the preform 50 is formed using the molding stack 700positioned in the molding system 100. More specifically, the preform 50is molded in a mold cavity defined at least in part between a mold core710 and a mold cavity portion 730 (as well as neck rings 720) of themolding system 100.

The preform 50 is then removed from the mold cavity portion 730, thepreform remaining on a mold core 710. The mold core 710, with thepreform 50 still disposed thereon, is then placed in a container mold770 having an internal surface 775 (similar to those described above,see FIG. 18 ).

The preform 50 is then stretched into conformity with the internalsurface 775 of the mold cavity 770 by filling an interior of the preform50 with the liquid through a channel 715 defined in the mold core 710,pressure of the liquid entering the preform 50 through the mold core 710causing the preform 50 to expand.

In some embodiments of the present technology, the steps of locating andthe stretching are performed before the preform 50 has cooled to athreshold temperature.

Preform-Preblowing-Liquiforming

With reference to FIGS. 19 to 21 , yet another embodiment is depicted ofa process 800 and a method 900 for forming and filling the final-shapedcontainer 15 using the liquid product to be contained in thefinal-shaped container 15.

With reference to FIG. 19 , the process 800 will be described in moredetail.

Stage 820

In accordance with these non-limiting embodiments of the presenttechnologies, the preform 50 is formed using the molding system 100.More specifically, the preform 50 is molded in a mold cavity defined atleast in part between a mold core and a mold cavity portion (as well asneck rings) of the molding system 100.

The preform 50 is then removed from the mold cavity portion, the preformremaining on a mold core. The preform 50 is then removed from the moldcore by the robot 122.

Stage 840

The preform 50 is then pre-processed into a prepared preform by blowinga base portion of the preform to a stretched size, the stretched sizebeing less than the size of a base of the final-shaped container. Inother embodiments, the preform could be prepared by partially blowing adifferent portion than the base portion, or additional portions of thepreform.

In some embodiments of the present technology, the pre-processing can bedone in the robot 122 (see for example, FIG. 20 ). In such anembodiment, the robot 122 would include a forming cavity (FIG. 20 , notseparately numbered) adapted for forming the prepared preform. Someexamples of the modifications that may be required to the robot 122 aredepicted in FIG. 20 .

In other embodiments of the present technology, the pre-processing canbe done in a forming cavity of a preparation station, the preparationstation being separate from the forming machine and the robot 122.

Stage 860

The prepared preform is then relocated to a forming cavity of a formingmachine for simultaneously forming and filling using the liquid to becontained in the final-shaped container 15, the forming cavity having aninternal surface.

With reference to FIG. 21 , there is depicted a flow chart of a method900 for forming and filling the final-shaped container.

Step 910

Forming the preform 50 by injection molding in the molding system 100.

Step 920

Removing the preform 50 from the molding system 100 by the robot 122.

Step 930

Forming the prepared preform by blowing a base portion of the preform 50to a stretched size, the stretched size being less than the size of abase of the final-shaped container 15.

In some embodiments, the forming the prepared preform at step 930 isperformed by the robot 122. In other embodiments, the forming theprepared preform at step 930 is performed by another device, separatefrom the robot 122 and from the forming system.

Step 940

Relocating the prepared preform to a forming cavity of a forming machinefor simultaneously forming and filling using the liquid to be containedin the final-shaped container, the forming cavity having an internalsurface.

Step 950

Sealably connecting the nozzle onto an opening of the prepared preform.

Step 960

Stretching the prepared preform into conformity with the internalsurface of the forming cavity by filling an interior of the preform withthe liquid through the nozzle, pressure of the liquid entering theprepared preform causing the prepared preform to expand.

Depending on the specific implementation, any of the above describedapparatuses or systems could be adapted for stretching the preparedpreform.

The invention claimed is:
 1. A method of simultaneously forming andfilling a final-shaped container from a preform using a liquid, theliquid being a product to be contained in the final-shaped container,the method comprising: locating the preform in a mold cavity having aninternal surface; sealably connecting a nozzle onto an opening of thepreform; inserting a stretch rod through the nozzle into the opening ofthe preform, at least a lower portion of the stretch rod sealablyconnecting with an interior surface of the preform to at least partiallyisolate a gate portion; and stretching the preform into conformity withthe internal surface of the mold cavity by: filling an interior of thepreform with the liquid through the nozzle, and extending the stretchrod farther into the gate portion.
 2. The method of claim 1, wherein:the stretch rod includes a deformable member configured to at leastpartially isolate the gate portion of the preform from the liquid whenextended; and when filling the interior of the preform with the liquidthrough the nozzle, the liquid causes the deformable member to extendout from the stretch rod to contact the interior surface of the preformto form a temporary seal to at least partially isolate the gate portionfrom the liquid.
 3. The method of claim 2, wherein the deformable memberis a rubber cup disposed about a lower portion of the stretch rod. 4.The method of claim 3, wherein the rubber cup radially extends from thestretch rod.
 5. The method of claim 3, wherein the deformable member isrepositionable between an engaged configuration and a disengagedconfiguration, in the disengaged configuration the deformable memberbeing dimensioned to pass through a neck opening of the preform.
 6. Themethod of claim 5, wherein the deformable member is repositioned intothe engaged configuration by the pressure of the liquid filling theinterior of the preform.
 7. The method of claim 5, wherein thedeformable member is repositioned into the disengaged configuration by adecrease in the pressure of the liquid filling the interior of thepreform.
 8. The method of claim 1, wherein: the stretch rod includes acontrollably-extendible sealing member for selectively and at leastpartially isolating the gate portion of the preform from the liquid; andwherein the method further comprises: actuating thecontrollably-extendible sealing member to extend out from the stretchrod to contact the interior surface of the preform to form a temporaryseal for at least partially isolating the gate portion.
 9. The method ofclaim 8, wherein the controllably-extendible sealing member is actuatedby a machine control unit operatively connected to the stretch rod. 10.The method of claim 1, wherein: the stretch rod includes a selectivelyheatable tip; and wherein the method further comprises activating theselectively heatable tip for heating at least the gate portion of thepreform before the stretching of the preform.
 11. The method of claim 1,further comprising, prior to the stretching the preform into conformitywith the internal surface of the mold cavity: performing a preliminarystretch of the preform by molding the preform to a partially stretchedconfiguration.
 12. The method of claim 2, wherein the deformable memberis a rubber air bladder disposed about a lower portion of the stretchrod.
 13. The method of claim 12, wherein: the rubber air bladder isrepositionable between an engaged configuration and a disengagedconfiguration; in the disengaged configuration, the rubber air bladderis dimensioned to pass through a neck opening of the preform; and therubber air bladder is converted from the disengaged configuration to theengaged configuration by inflating the rubber air bladder.
 14. Themethod of claim 1, wherein: the stretch rod includes acontrollably-deformable rubber air bladder for selectively and at leastpartially isolating the gate portion of the preform from the liquid; andwherein the method further comprises: inflating thecontrollably-deformable rubber air bladder to extend out from thestretch rod to contact the interior surface of the preform to form atemporary seal for at least partially isolating the gate portion.